Polycrystalline diamond compacts with partitioned substrate, polycrystalline diamond table, or both

ABSTRACT

Methods for at least partially relieving stress within a polycrystalline diamond (“PCD”) table of a polycrystalline diamond compact (“PDC”) include partitioning the substrate of the PDC, the PCD table of the PDC, or both. Partitioning may be achieved through grinding, machining, laser cutting, electro-discharge machining, or combinations thereof. PDCs may include at least one stress relieving partition.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/234,252 filed on 16 Sep. 2011, which is a continuation-in-part ofU.S. patent application Ser. No. 13/116,566 filed 26 May 2011 and acontinuation-in-part of U.S. patent application Ser. No. 13/166,007filed 22 Jun. 2011. Each of the foregoing applications is incorporatedherein, in its entirety, by this reference.

BACKGROUND

Wear-resistant, polycrystalline diamond compacts (“PDCs”) are utilizedin a variety of mechanical applications. For example, PDCs are used indrilling tools (e.g., cutting elements, gage trimmers, etc.), machiningequipment, bearing apparatuses, wire-drawing machinery, and in othermechanical apparatuses.

PDCs have found particular utility as superabrasive cutting elements inrotary drill bits, such as roller-cone drill bits and fixed-cutter drillbits. A PDC cutting element typically includes a superabrasive diamondlayer commonly known as a diamond table. The diamond table is formed andbonded to a substrate using a high-pressure/high-temperature (“HPHT”)process. The PDC cutting element may be brazed directly into a preformedpocket, socket, or other receptacle formed in a bit body. The substratemay often be brazed or otherwise joined to an attachment member, such asa cylindrical backing. A rotary drill bit typically includes a number ofPDC cutting elements affixed to the bit body. It is also known that astud carrying the PDC may be used as a PDC cutting element when mountedto a bit body of a rotary drill bit by press-fitting, brazing, orotherwise securing the stud into a receptacle formed in the bit body.

Conventional PDCs are normally fabricated by placing a cemented carbidesubstrate into a container or cartridge with a volume of diamondparticles positioned on a surface of the cemented carbide substrate. Anumber of such cartridges may be loaded into an HPHT press. Thesubstrate(s) and volume(s) of diamond particles are then processed underHPHT conditions in the presence of a catalyst material that causes thediamond particles to bond to one another to form a matrix of bondeddiamond grains defining a polycrystalline diamond (“PCD”) table. Thecatalyst material is often a metal-solvent catalyst (e.g., cobalt,nickel, iron, or alloys thereof) that is used for promoting intergrowthof the diamond particles.

In one conventional approach, a constituent of the cemented carbidesubstrate, such as cobalt from a cobalt-cemented tungsten carbidesubstrate, liquefies and sweeps from a region adjacent to the volume ofdiamond particles into interstitial regions between the diamondparticles during the HPHT process. The cobalt acts as a catalyst topromote intergrowth between the diamond particles, which results information of a matrix of bonded diamond grains having diamond-to-diamondbonding therebetween, with interstitial regions between the bondeddiamond grains being occupied by the solvent catalyst. Once the PCDtable is formed, the solvent catalyst may be at least partially removedfrom the PCD table of the PDC by acid leaching.

SUMMARY

Various embodiments of the present invention are directed to methods ofrelieving residual stresses within a PCD table of a PDC. At leastpartial relief of such stresses reduces the tendency of the PCD table(which may be relatively brittle) to crack or otherwise fracture duringuse as a result of an impact or similar event. According to anembodiment of a method, a PDC including a PCD table bonded to asubstrate (e.g., tungsten carbide or other carbide substrate) isprovided. The PCD table includes a plurality of diamond grains that arebonded together. In order to at least partially relieve stress, the PCDtable, the substrate, or both are partitioned (e.g., by EDM cutting,laser cutting, grinding, etc.).

Other embodiments are directed to associated PDCs that include a stressrelieving partition formed into at least one of the substrate or PCDtable. Such a PDC may include a substrate, a PCD table including aplurality of bonded diamond grains in which the PCD table is bonded tothe substrate. The PCD table includes an exterior working surface and atleast one lateral surface. At least one stress relieving partition isformed into at least one of the substrate or the PCD table to at leastpartially relieve stress within the PCD table.

The inventors have discovered that such partitioning of at least one ofthe PCD table or substrate decreases the residual stress within the PCDtable, providing improved durability. In addition, partitioning of thePCD table provides a boundary that can stop propagation of a crackwithin the PCD table, should a crack form. Stopping progression of sucha crack allows damage to be limited to and contained within one portionof the PCD table, preventing it from spreading to other portions acrossthe partition.

Features from any of the disclosed embodiments may be used incombination with one another, without limitation. In addition, otherfeatures and advantages of the present disclosure will become apparentto those of ordinary skill in the art through consideration of thefollowing detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate several embodiments of the invention, whereinidentical reference numerals refer to identical or similar elements orfeatures in different views or embodiments shown in the drawings.

FIG. 1 is an isometric view of an example PDC;

FIG. 2 is a flow diagram describing an embodiment of a method forpartitioning a substrate, PCD table, or both of a PDC in order torelieve residual stresses within the PCD table;

FIG. 3 is an isometric view of a PDC including a partitioning cut formedinto the PCD table according to an embodiment;

FIGS. 3A-3C are cross-sectional views of PDCs including a partitionformed into the PCD table and in which the respective partitioning cutsextend to different lengths relative to the location of an interfacebetween the PCD table and the substrate according to variousembodiments;

FIG. 3D is an isometric view of a PDC including a domed PCD layerincluding partitioning cuts formed into the domed PCD table;

FIGS. 4A-4C are top plan views of PDCs similar to that shown in FIG. 3,but including different partition configurations according to variousembodiments;

FIGS. 5A-5D are cross-sectional views of PDCs including a partitionformed into the substrate and in which the respective partitioning cutsextend to different lengths relative to the location of an interfacebetween the substrate and the PCD table according to variousembodiments;

FIG. 6 is a graph showing residual stresses for PCD tables as a resultof various partitioning configurations;

FIGS. 7A-7C are isometric views of various embodiments of PDCs includinga spring mechanism formed into the substrate of the PDC in order toincrease the ability of the adjacent PCD table to flex and absorb energyas a result of an impact;

FIG. 7D is a cross-sectional view of another embodiment of a PDCincluding a spring mechanism disposed within the substrate of the PDC;

FIG. 8 is an isometric view of an embodiment of a rotary drill bit thatmay employ one or more PDCs according to any of the disclosedembodiments;

FIG. 9 is a top elevation view of the rotary drill bit shown in FIG. 8;

FIG. 10 is an isometric cut-away view of an embodiment of athrust-bearing apparatus that may employ one or more PDCs according toany of the disclosed embodiments;

FIG. 11 is an isometric cut-away view of an embodiment of a radialbearing apparatus that may employ one or more PDCs according to any ofthe disclosed embodiments; and

FIG. 12 is a schematic isometric cut-away view of an embodiment of asubterranean drilling system including the thrust-bearing apparatusshown in FIG. 10.

DETAILED DESCRIPTION I. Introduction

Embodiments of the present invention are directed to PDCs including asubstrate, and a PCD table including a plurality of bonded diamondgrains that is bonded to the substrate. The PCD table includes anexterior working surface and at least one lateral surface. At least onestress relieving partition is formed into the substrate, the PCD table,or both to at least partially relieve stress within the PCD table. Atleast partial relief of the residual stresses of the PCD table improvesthe overall durability of the PCD table. Further embodiments of thepresent invention are directed to related methods of fabricating suchPDCs including one or more stress relieving partitions formed into thesubstrate, PCD table, or both.

II. PDC Embodiments

The PCD elements partitioned for at least partial stress reliefdisclosed herein include PCDs fabricated according to one-step andtwo-step methods, as discussed in more detail hereinbelow. It may alsobe possible to form a partition into a freestanding PCD table orsubstrate, prior to final bonding of the two together. A one-step PDCmay include a PCD table integrally formed and bonded to a cementedcarbide substrate. The PCD table includes directly bonded-togetherdiamond crystals exhibiting diamond-to-diamond bonding (e.g., sp³bonding) therebetween that define a plurality of interstitial regions.An example PDC 100 including a PCD table 102 and a cemented carbidesubstrate 104 is shown in FIG. 1. The PCD table 102 includes at leastone lateral surface 105, an upper exterior working surface 103, and mayinclude an optional chamfer 107 formed therebetween. It is noted that atleast a portion of the at least one lateral surface 105 and/or thechamfer 107 may also function as a working surface (e.g., that contactsa subterranean formation during drilling operations).

A metal-solvent catalyst (e.g., iron, nickel, cobalt, or alloys thereof)is disposed in at least a portion of the interstitial regions betweenadjacent diamond crystals of PCD table 102. The cemented carbidesubstrate 104 may comprise tungsten carbide, tantalum carbide, vanadiumcarbide, niobium carbide, chromium carbide, titanium carbide, orcombinations of the foregoing carbides cemented with iron, nickel,cobalt, or alloys of the foregoing metals. For example, the cementedcarbide substrate may comprise cobalt-cemented tungsten carbide.

Generally, a one-step PDC may be formed by placing un-bonded diamondparticles adjacent to a cemented carbide substrate and subjecting thediamond particles and the cemented carbide substrate to an HPHT processunder diamond stable HPHT conditions. During the HPHT process,metal-solvent catalyst from the cemented carbide substrate at leastpartially melts and sweeps into interstitial regions between the diamondcrystals to catalyze growth of diamond and formation ofdiamond-to-diamond bonding between adjacent diamond particles so that aPCD table is formed that bonds to the cemented carbide substrate uponcooling from the HPHT process.

A two-step PDC may also be formed in which an at least partially leachedPCD table (i.e., a freestanding PCD table) may be placed adjacent to acemented carbide substrate and subjected to an HPHT process underdiamond stable conditions. During the HPHT process, an infiltrant fromthe cemented carbide substrate infiltrates into the interstitial regionsof the at least partially leached PCD table and bonds the infiltratedPCD table to the cemented carbide substrate upon cooling from the HPHTprocess.

In an embodiment, the at least partially leached PCD table may be formedby separating the PCD table from a one-step PDC by removing the cementedcarbide substrate via any suitable process (e.g., grinding, machining,laser cutting, EDM cutting, or combinations thereof). The metal-solventcatalyst present within the PCD table may be leached from the PCD tablein a suitable acid. In another embodiment, the at least partiallyleached PCD table may be formed by other methods, such as sinteringdiamond particles in the presence of a metal-solvent catalyst to form aPCD table or disk and leaching the PCD table in a suitable acid.

After bonding to a final substrate, both one-step and two-step PDCs maybe subjected to a leaching process to remove a portion of themetal-solvent catalyst or infiltrant from the PCD table to a selecteddepth and from one or more exterior surfaces. Removal of themetal-solvent catalyst or infiltrant may help improve thermal stabilityand/or wear resistance of the PCD table during use.

Examples of acids used in leaching include, but are not limited to, aquaregia, nitric acid, hydrofluoric acid, and mixtures thereof. Forexample, leaching the PCD table 102 may form a leached region thatextends inwardly from the exterior surface 103, the lateral surface 105,and the chamfer 107 to a selected leached depth. Such a selected leacheddepth may be about 100 μm to about 1000 μm, about 100 μm to about 300μm, about 300 μm to about 425 μm, about 350 μm to about 400 μm, about350 μm to about 375 μm, about 375 μm to about 400 μm, about 500 μm toabout 650 μm, or about 650 μm to about 800 μm.

The bonded together diamond grains of the PCD table may exhibit anaverage grain size of about 100 μm or less, about 40 μm or less, such asabout 30 μm or less, about 25 μm or less, or about 20 μm or less. Forexample, the average grain size of the diamond grains may be about 10 μmto about 18 μm, about 8 μm to about 15 μm, about 9 μm to about 12 μm, orabout 15 μm to about 25 μm. In some embodiments, the average grain sizeof the diamond grains may be about 10 μm or less, such as about 2 μm toabout 5 μm or submicron.

The diamond particle size distribution of the diamond particles mayexhibit a single mode, or may be a bimodal or greater grain sizedistribution. In an embodiment, the diamond particles of the one or morelayers of diamond particles may comprise a relatively larger size and atleast one relatively smaller size. As used herein, the phrases“relatively larger” and “relatively smaller” refer to particle sizes (byany suitable method) that differ by at least a factor of two (e.g., 30μm and 15 μm). According to various embodiments, the diamond particlesmay include a portion exhibiting a relatively larger average particlesize (e.g., 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 12 μm, 10 μm, 8 μm) andanother portion exhibiting at least one relatively smaller averageparticle size (e.g., 6 μm, 5 μm, 4 μm, 3 μm, 2 μm, 1 μm, 0.5 μm, lessthan 0.5 μm, 0.1 μm, less than 0.1 μm). In an embodiment, the diamondparticles may include a portion exhibiting a relatively larger averageparticle size between about 10 μm and about 40 μm and another portionexhibiting a relatively smaller average particle size between about 1 μmand 4 μm. In some embodiments, the diamond particles may comprise threeor more different average particle sizes (e.g., one relatively largeraverage particle size and two or more relatively smaller averageparticle sizes), without limitation.

It is noted that the as-sintered diamond grain size may differ from theaverage particle size of the diamond particles prior to sintering due toa variety of different physical processes, such as grain growth, diamondparticles fracturing, carbon provided from another carbon source (e.g.,dissolved carbon in the metal-solvent catalyst), or combinations of theforegoing.

The PCD table 102 may exhibit a thickness of at least about 0.040 inch,such as about 0.045 inch to about 1 inch, about 0.045 inch to about0.500 inch, about 0.050 inch to about 0.200 inch, about 0.065 inch toabout 0.100 inch, or about 0.070 inch to about 0.100 inch (e.g., about0.09 inch).

As described above, the PCD table 102 may be formed separately from orintegral with the substrate 104 in an HPHT process. When formedseparately, the PCD table 102 may be subsequently attached to thesubstrate 104 in another HPHT process (i.e., the PCD is fabricated in atwo-step process). The temperature of such HPHT processes may typicallybe at least about 1000° C. (e.g., about 1200° C. to about 1600° C.) andthe pressure of the HPHT process may typically be at least about 4.0 GPa(e.g., about 5.0 GPa to about 12.0 GPa, about 7.0 GPa to about 9.0 GPa,about 6.0 GPa to about 8.0 GPa, or about 9.0 GPa to about 12.0 GPa).Techniques for brazing the PCD table to the substrate are disclosed inU.S. Pat. No. 8,236,074, which is incorporated by reference below.

Additional details of examples of one-step and two-step processes forfabricating a PDC are disclosed in U.S. application Ser. No. 12/961,787filed 7 Dec. 2010; U.S. Pat. No. 8,236,074 issued on 7 Aug. 2012; andU.S. Pat. No. 7,866,418 issued on 11 Jan. 2011, both of which areincorporated herein, in their entirety, by this reference. Any PDC orPCD table disclosed in U.S. application Ser. No. 12/961,787; U.S. Pat.No. 8,236,074; and U.S. Pat. No. 7,866,418 may be used as the initialPDC or PCD table that is partitioned.

III. Embodiments of Partitioned PDCs and Fabrication Methods

FIG. 2 shows a flow diagram generally describing an embodiment of amethod S10 for at least partially relieving residual stresses within aPCD table of the PDC. At S12, a PDC including a PCD table bonded to asubstrate is provided. The PCD table includes a plurality of diamondgrains that are bonded together. The PDC may be similar to that shown inFIG. 1. Because of differences between the coefficient of thermalexpansion (“CTE”) of the substrate relative to that of the PCD table,inherent residual stresses are present within the PDC structure. Atleast a portion of the residual stresses can be relieved by forming apartition (e.g., a cut) into the PCD table, the substrate, or both. AtS14, such a partition is formed into the PCD table, the substrate orboth. The modified PDC including one or more partitions exhibits adecreased level of residual stress within the PCD table, which mayimprove the durability and usability of the PDC, even if it is damagedduring use. For example, the partition can arrest or direct propagationof a crack in the PCD table at the partition should a crack form duringuse.

FIG. 3 is an isometric view of a PDC 200 including a partition 208formed into PCD table 102. The partitioning cut 208 is shown as beinggenerally aligned with a diameter of the PCD table 102, partitioningtable 102 into two substantially equal portions 102 a and 102 b. Thepartitioning cut 208 is shown as extending nearly to interface 110between the substrate 104 and the PCD table 102 (e.g., leaving a PDCtable thickness of less than about 0.1 inch). The partitioning cut 208may be disposed entirely within PCD table 102 (as shown), may extend tothe interface 110, or may even extend somewhat past the interface 110into the substrate 104.

Extension of the partitioning cut 208 beyond the interface 110 may bebeneficial where the PCD table 102 has been sintered with the substrate104 to at least partially relieve stresses associated with a zone of thesubstrate 104 adjacent interface 110 that is depleted of metal-solventcatalyst relative to adjacent deeper portions of the substrate 104. Themetal-solvent catalyst depletion zone may be more brittle than adjacentregions in the substrate including higher cobalt or other metal solventcatalyst levels. As a result, the cut 208 may advantageously extend intoor past such a depletion zone. For example, during sintering andbonding, a metal-solvent catalyst or infiltrant is swept into the regionof the PCD table 102, thereby depleting a portion of the substrate 104of cobalt or other metal-solvent catalyst/infiltrant that is disposedadjacent to the interface 110. The partitioning cut 208 may be extendedinto a depletion zone or past this zone of the substrate 104 to betterrelieve stresses resulting from the presence of the depleted zoneadjacent the PDC table 102.

Where the partitioning cut 208 extends short of the interface 110 (so asto be entirely disposed within PCD table 102), the partitioning cut 208may leave a PCD table thickness between greater than 0 and about 0.1inch, between about 0.005 inch and about 0.07 inch, or between about0.05 inch and about 0.1 inch. FIG. 3A shows an embodiment in which theportioning cut 208 is entirely disposed within the PCD table 102,leaving a PCD thickness as described above. FIG. 3B shows an embodimentin which the portioning cut 208 extends to the interface 110. FIG. 3Cshows an embodiment in which the portioning cut 208 extends beyond theinterface 110, into the substrate 104.

Where the partitioning cut 208 extends through PCD table 102 and intosubstrate 104 (e.g., into or even deeper than a depletion zone), thepartitioning cut 208 may extend between greater than 0 and about 0.1inch into substrate 104, between about 0.005 inch and about 0.07 inchinto substrate 104, or between about 0.008 inch and about 0.1 inch intosubstrate 104. In an embodiment, a depletion zone may typically extendto a depth between about 0.008 inch to about 0.05 inch.

The width of partitioning cut 208 may be of any desired value. In oneembodiment, the partitioning cut 208 may be formed by EDM or lasercutting. The width of the partitioning cut 208 may be about 0.001 inchto about 0.2 inch, about 0.005 inch to about 0.05 inch, about 0.01 inchto about 0.1 inch, about 0.0001 to about 0.001 inch, or less than about0.001 inch.

FIG. 3D is an isometric view of a PDC 200′ including a substrate 104′bonded to a PCD layer 102′ with a convexly-curved top working surface103′. As with the illustrated planar PCD table configurations, thesubstrate, PCD layer, or both of such a PDC may be partitioned to atleast partially relieve stresses. In an embodiment, a plurality ofpartitioning cuts 208′ may be formed about a periphery of the PCD layer102′ proximate to the interface surface 110′ between the PCD layer 102′and the substrate 104′. Such domed or otherwise curved PCD layers mayparticularly benefit from partitioning, as such PDCs may exhibit greaterinternal stresses than planar PCD tables, which can lead to delaminationor other premature failure of the PCD layer. As illustrated, thepartitioning cuts 208′ may be formed into the convexly-curved topworking surface 103′ of the PCD layer 102′. For example, the one or morepartitioning cuts 208′ may terminate at the interfacial surface 110′ ormay extend beyond the interfacial surface 110′ into the substrate 104′(shown with the broken lines).

FIGS. 4A-4C illustrate top plan views of various embodiments ofconfigurations by which PCD table 102 may be partitioned. FIG. 3illustrates an embodiment where a single partitioning cut 208 dividesthe PCD table 102 into the two portions 102 a, 102 b. FIG. 4Aillustrates an embodiment where the PCD table 102 is partitioned intofour substantially equal portions 302 a-302 d. Two partitioning cuts 308may be formed in a top surface of PCD table 102, along the diameter ofPCD table 102 so as to intersect substantially perpendicularly. FIG. 4Billustrates an embodiment where the PCD table 102 is partitioned intothree substantially equal portions 402 a-402 c where three partitioningcuts 408 are spaced about 120° apart. Each cut 408 is located at aradius of PCD table 102, each spaced about 120° apart. FIG. 4C showsanother embodiment similar to that of FIG. 4B, but in which a centralgenerally circular partitioning cut 508 c is also formed. The radiuspartitioning cuts 508 do not extend to the center of PCD table 102, butend at the intersection with central generally circular cut 508 c. Thegenerally circular partitioning cut 508 c defines a central portion 502d, while the other partitioning cuts 508 further define boundaries ofportions the 502 a-502 c. As described above, partitioning of the PCDtable 102 may extend short of the interface 110, to the interface 110,or beyond the interface 110 and into the substrate 104 (e.g., past adepleted zone). In an embodiment, the PCD table may be completelypartitioned (e.g., the cuts may extend to the interface 110), and thePCD table may subsequently be bonded back together (e.g., by HPHTprocessing with an associated substrate). Alternative partitioningconfigurations are possible, e.g., along various radius positionssimilar to the embodiment shown in FIG. 3D. For example, thepartitioning cut(s) may not be disposed along a radius or diameter, butoffset so as to divide the partitioned component into portions of anydesired size or shape. The illustrated configurations are onlyembodiments, and various other partitioning configurations may beemployed.

FIGS. 5A-5C illustrate cross-sectional views of various configurationsby which the substrate of PDC 100 may be partitioned. The substrate maybe partitioned in any configuration desired, for example, similar to thetwo, three, or four portions shown with respect to partitioning of PCDtable 102 in FIGS. 3 and 4A-4C. Of course, other partitioningconfigurations will also be apparent to one of skill in the art. As withpartitioning the PCD table 102, partitioning of the substrate 104 mayextend to the interface 110, short of the interface 110, or extend pastinterface the 110 (i.e., into the PCD table 102). FIG. 5A shows apartitioning cut 608 of the substrate 104 terminating generally at theinterface 110 between the substrate 104 and the PCD table 102 accordingto an embodiment. FIGS. 5B and 5C both show configurations in which thepartitioning cut 608 terminates short of the interface 110 so that theentirety of the partitioning cut 608 is disposed within substrate the104 according to an embodiment. FIG. 5D shows an example in whichpartitioning cut 608 extends beyond the interface 110, into the PCDtable 102. In addition, although the interface 110 is shown in thevarious Figures as being generally planar, this is not required. Forexample, the interface 110 may be non-planar (e.g., curved, having aplurality of projections, having a plurality of recesses, orcombinations of the foregoing), or may provide for varying thickness ofthe adjacent substrate, PCD table, or both. Of course, additionalpartitioning cuts may be formed in the PCD table 102, if desired (e.g.,as shown in FIGS. 3 and 4A-4C), so that both the substrate and PCD tableare partitioned. Furthermore, when partitioning the exterior surfaces ofboth the substrate 104 and the PCD table 102, the partitions may beoffset relative to one another so as to not intersect one another forincreased strength.

Where the partitioning cut 608 extends short of the interface 110 so asto be entirely disposed within substrate 104, the partitioning cut 608may leave a substrate thickness between about 0 and about 0.1 inch,between about 0.005 inch and about 0.07 inch, or between about 0.05 inchand about 0.1 inch. By way of example, FIG. 5B may represent apartitioning cut 608 that extends to within about 0.01 inch (e.g., about0.01 inch or less) from the interface 110. FIG. 5C may represent apartitioning cut 608 that extends to within about 0.05 inch (e.g., about0.05 inch or less) from the interface 110.

The partitioning cuts may be formed by any suitable technique,including, but not limited to, grinding, machining, laser cutting,electro-discharge machining (“EDM”), combinations thereof, or othersuitable technique. Suitable EDM techniques includes plunge EDM, wireEDM, or combinations thereof, without limitation. The foregoing materialremoval techniques remove a selected amount of material from thesubstrate 104, the PCD table 102, or both, to form the portioning cutwith a desired depth and width. Typical widths for the partitioning cut608 may be about 0.001 inch to about 0.2 inch, about 0.005 inch to about0.05 inch, about 0.01 inch to about 0.1 inch, about 0.0001 to about0.001 inch, or less than about 0.001 inch. When partitioning a PCD tablethat has been leached, it may be desirable to form the partitioning cutsby laser cutting, which does not require that the PCD table beelectrically conductive. Additional details relative to laser cuttingembodiments are disclosed in U.S. patent application Ser. No. 13/166,007filed Jun. 22, 2011 and entitled METHOD FOR LASER CUTTINGPOLYCRYSTALLINE DIAMOND STRUCTURES, which is incorporated herein, in itsentirety, by this reference.

FIG. 6 shows actual testing data associated with partitioning cuts 608similar to those shown in FIGS. 5A-5C, in which the substrate ispartitioned. As shown, a standard PDC including no partitioning cutsexhibits residual stress values within the PCD table that are quitevariable depending on the thickness of the substrate. The residualstress data is calculated by measuring the strain relieved in the PCDtable as the substrate is progressively ground away. Stress may becalculated from the measured relieved strain values assuming a modulusof elasticity (E) of 1.24×10⁸ psi and a Poisson's ratio (v) of 0.23 forthe PCD table. Such a technique is described in Lin, T. P., Hood, M.,Cooper, G. A., & Smith, R. H. (1994). Residual stresses inpolycrystalline diamond compacts. Journal of the American CeramicSociety, 77, 1562-1568, which is incorporated herein, in its entirety,by this reference. For example, in a conventional PDC withoutpartitioning (e.g., the PDC 100 of FIG. 1) a peak tensile residualstress within the PCD table of about 5.00×104 psi is found at asubstrate thickness of about 0.06 inch. As the substrate thicknessincreases, the residual stress values drop, eventually reaching amaximum compressive residual stress of about 6.00×10⁴ psi.

When the substrate is partitioned (e.g., as shown in FIG. 5A) generallyto the PCD table-substrate interface, the residual stress profile as afunction of substrate thickness is very different from the standard PDC.The residual stress is tensile in character no matter the thickness ofthe substrate, and is relatively constant, remaining between about0.5×10⁴ psi to about 1×10⁴ psi. When the substrate is partitioned (e.g.,as shown in FIG. 5B) to a distance about 0.01 inch from the PCDtable-substrate interface, the residual stress profile is similar,although somewhat higher. The residual stress is tensile in character nomatter the substrate thickness, and is relatively constant, remainingbetween about 1×10⁴ psi to about 1.75×10⁴ psi. When the substrate ispartitioned (e.g., as shown in FIG. 5C) to a distance about 0.05 inchfrom the PCD table-substrate interface, the residual stress profile isagain similar, although higher still. The residual stress is stilltensile in character no matter the substrate thickness, and isrelatively constant, remaining between about 4×10⁴ psi to about 4.5×10⁴psi.

As shown in FIGS. 7A-7C, some embodiments may further include a springmechanism 112 within substrate 104 to allow the adjacent PCD table 102to flex and better absorb energy as a result of an impact. Variousspring mechanisms 112 may be formed into substrate 104 by removal ofselect portions of substrate 104. FIG. 7A shows an embodiment of a PDC700 including a PCD table 102 that has been partitioned by twosubstantially perpendicular diameter cuts 708 (i.e., similar to thatshown in FIG. 4A). A substrate 104 is bonded to the PCD table 102 at theinterface 110. The spring mechanism 112 includes a plurality ofgenerally longitudinally extending (i.e., vertical in the orientation ofFIG. 7A) relief cuts 114, which may be similar to partitioning cuts 608described above. Such relief cuts 114 may typically not extend the fullwidth of substrate 104, but be formed in an outer peripheral surface andextend partially into the substrate 104 to a selected depth. While suchrelief cuts 114 may also provide stress relief as described aboverelative to the partitioning cuts 608, the relief cuts 114 may provide aspring mechanism within the substrate 104 for improved impact resistancefor the PCD table 102. The cuts 114 may be formed to any desired depth,and may extend towards the center of PDC 100, defined along longitudinalaxis A (e.g., cuts 114 may be formed along radius lines extendingoutward from axis A). According to an embodiment, formation of thespring mechanism 112 may be accomplished by bonding a solid backupsubstrate portion to a partitioned substrate portion. Providing a solidbackup substrate portion may add strength to the substrate and may beformed from any of the cemented carbide materials disclosed herein. FIG.7A illustrates one such embodiment, where the substrate 104 includes asolid backup bottom portion 104 a and a partitioned top portion 104 b.The two portions 104 a and 104 b may be bonded together along interface110 a via brazing, diffusion bonding, or an HPHT bonding process.

FIG. 7B shows another embodiment of a configuration 700′ similar to thePDC 700 shown in FIG. 7A, but in which the spring mechanism 112′comprises a helically extending groove 116 extending around a periphery(e.g., a circumference) of the substrate 104. The height “H” and depth“D” of the helical groove 116 may be selected depending on desiredspring characteristics. For example, the depth “D” may be about 0.01 toabout 0.5 times a diameter or other lateral dimension of the PDC 700′,such as about 0.02 cm to about 1 cm, or about 0.6 cm to about 0.8 cm.The height “H” may be about 0.001 inch to about 0.2 inch, about 0.005inch to about 0.05 inch, or about 0.01 inch to about 0.1 inch. FIG. 7Cshows another embodiment of a configuration 700″ similar to the PDC 100shown in FIG. 7B, but in which the spring mechanism 112″ comprises agroove 118 that is not helical, but extends around the substrate 104 ata substantially constant distance from the interface 110.

As seen in FIGS. 7A-7C, the spring mechanism may be provided adjacent tothe interface 110. The spring mechanism may extend substantially thefull height of the substrate 104, or (as shown), may be disposed withinonly a “top” portion of the substrate 104, adjacent to the interface 110so as to be disposed in close proximity to the PCD table 102.

In each case, the disclosed spring mechanism 112 provides an improvedability for the adjacent PDC table 102 to flex and absorb energy as aresult of an impact. In other words, a given impact that would result infracture of the PCD table of a PDC (e.g., such as that shown in FIG. 1)that does not include a spring mechanism may comparatively exhibit adifferent outcome when a spring mechanism (e.g., as shown in FIGS.7A-7C) is included in the substrate 104. As compared to the standardPDC, a PDC as shown in FIGS. 7A-7C may be expected to exhibit less of atendency for the PCD table to fracture when subjected to a given impact.As such, the PDCs and PCD tables may exhibit increased durability. Suchconfigurations may be particularly beneficial for drilling applicationswhen encountering a hard rock formation. It may also be beneficial withimpact loading.

In some embodiments, a compliant material (e.g., a rubber or otherpolymer such as silicone or a thermoplastic elastomer) may be disposedwithin the groove to provide a selected stiffness to the springmechanism.

Providing both partitioning of the PCD table and a spring mechanism asshown in FIGS. 7A-7C may be particularly beneficial, as the partitioningof the PCD table 102 at least partially relieves stresses within the PCDtable as shown in FIG. 6, while also limiting any damage to a PCD tableto the portion in which the crack first appears. In other words, thecrack may be able to propagate to the partition cut defining theboundary of the particular PCD table portion, but its progress may bearrested at this point by the presence of the partitioning cut. Inaddition, providing a spring mechanism as shown in FIGS. 7A-7C providesadditional durability to inhibit a crack from forming in the firstplace, as the impact can be at least somewhat absorbed by the springmechanism and the ability of the above PCD table to flex. Thus, a crackis less likely to form in the first instance, and if a crack does form(as the result of a relatively large magnitude impact), the damagecaused by the crack may be limited to the portion in which it forms ordirected along the partitioning cut.

Of course, it will be understood that a spring mechanism for improvingimpact resistance of the PCD table may be provided independently of anypartitioning of the PCD table or substrate. For example, a springmechanism may be provided where no partitioning is provided in the PCDtable 102 or substrate 104. FIG. 7D illustrates one such PDC 700′″including a PCD table 702 bonded to a substrate 704. A bottom portion ofsubstrate 704 may be received within a cavity 710 defined by a substratesleeve portion 706. The substrate sleeve portion 706 may include a baseportion 708 with a spring mechanism 712 disposed within the cavity 710.For example, the spring mechanism 712 may be a compression spring and/orother biasing element such as a resilient material.

As illustrated, the substrate portions 704 and 706 may provide agenerally flush periphery at their interface when the spring mechanism712 is compressed. The lower portion 705 of the substrate portion 704may be laterally smaller than the adjacent upper section of thesubstrate portion 704 so that the lower portion 705 may be receivedwithin the cavity 710 of the sleeve portion 706 of the substrate 704.The internal surface of the sleeve portion 706 may include a flangesurface 714 that is configured to abut against an oppositely disposedflange 716. Abutment between the flanges 714 and 716 provides a stop,which limits how far substrate portion 704 can be biased upwards by thespring mechanism 712. Although no partitioning cuts are shown in PCDtable 702 or the substrate portion 704, such cuts may optionally beprovided. Similarly, any of the embodiments shown in FIGS. 7A-7C mayhave the partitioning cuts formed in the PCD table 102 omitted.

IV. Applications of Products Including PDCs

The PDCs including features and/or formed according to the variousembodiments disclosed herein may be used as PDC cutting elements on arotary drill bit, within thrust bearing assemblies, rotary bearingassemblies, and other applications. For example, in a method accordingto an embodiment of the invention, one or more PDCs that have beenpartitioned according to any of the disclosed embodiments may beattached to a bit body of a rotary drill bit, brazed or otherwise joinedinto a bearing assembly, or otherwise incorporated into a desiredproduct. In one embodiment, partitioning cuts formed into the substratemay be at least partially filled with braze alloy or other material,e.g., when brazing or otherwise joining the PDC into a bearing assemblyor other product.

FIG. 8 is an isometric view and FIG. 9 is a top elevation view of anembodiment of a rotary drill bit 800 that includes at least one PDCconfigured and/or fabricated according to any of the disclosed PDCembodiments. The rotary drill bit 800 comprises a bit body 802 thatincludes radially and longitudinally extending blades 804 having leadingfaces 806, and a threaded pin connection 808 for connecting the bit body802 to a drilling string. The bit body 802 defines a leading endstructure for drilling into a subterranean formation by rotation about alongitudinal axis 810 and application of weight-on-bit. At least onePDC, configured according to any of the previously described PDCembodiments, may be affixed to the bit body 802. With reference to FIG.9, each of a plurality of PDCs 812 is secured to the blades 804 of thebit body 802 (FIG. 8). For example, each PDC 812 may include a PCD table814 bonded to a substrate 816. More generally, the PDCs 812 may compriseany PDC disclosed herein, without limitation.

In addition, if desired, in some embodiments, a number of the PDCs 812may not have been partitioned as described herein. Also,circumferentially adjacent blades 804 define so-called junk slots 820therebetween. Additionally, the rotary drill bit 800 includes aplurality of nozzle cavities 818 for communicating drilling fluid fromthe interior of the rotary drill bit 800 to the PDCs 812.

FIGS. 8 and 9 merely depict one embodiment of a rotary drill bit thatemploys at least one PDC in accordance with the disclosed embodiments,without limitation. The rotary drill bit 800 is used to represent anynumber of earth-boring tools or drilling tools, including, for example,core bits, roller-cone bits, fixed-cutter bits, eccentric bits,bi-center bits, reamers, reamer wings, or any other downhole toolincluding superabrasive compacts, without limitation.

The PDCs including one or more partitioning cuts according toembodiments disclosed herein may also be utilized in applications otherthan cutting technology. For example, the disclosed PDC embodiments maybe used in bearings or other articles of manufacture including at leastone PCD table or compact.

FIG. 10 is an isometric cut-away view of an embodiment of athrust-bearing apparatus 900, which may utilize any of the disclosed PDCembodiments as bearing elements. The thrust-bearing apparatus 900includes respective thrust-bearing assemblies 902. Each thrust-bearingassembly 902 includes an annular support ring 904 that may be fabricatedfrom a material, such as carbon steel, stainless steel, or anothersuitable material. Each support ring 904 includes a plurality ofrecesses (not labeled) that receives a corresponding bearing element906. Each bearing element 906 may be mounted to a corresponding supportring 904 within a corresponding recess by brazing, press-fitting, usingfasteners, or another suitable mounting technique. One or more, or allof bearing elements 906 may be partitioned according to any of thedisclosed embodiments. For example, each bearing element 906 may includea substrate 908 and a PCD table 910, with the PCD table 910 including abearing surface 912.

In use, the bearing surfaces 912 of one of the thrust-bearing assemblies902 bears against the opposing bearing surfaces 912 of the other one ofthe bearing assemblies 902. For example, one of the thrust-bearingassemblies 902 may be operably coupled to a shaft to rotate therewithand may be termed a “rotor.” The other one of the thrust-bearingassemblies 902 may be held stationary and may be termed a “stator.”

FIG. 11 is an isometric cut-away view of an embodiment of a radialbearing apparatus 1000, which may employ PDCs that have been partitionedaccording to any of the disclosed embodiments. The radial bearingapparatus 1000 includes an inner race 1002 positioned generally withinan outer race 1004. The outer race 1004 includes a plurality of bearingelements 1006 mounted thereto that have respective bearing surfaces1008. For such a radial bearing, the bearing surface 1008 of elements1006 mounted to outer race 1004 may be concavely curved. The inner race1002 also includes a plurality of bearing elements 1010 affixed theretothat have respective bearing surfaces 1012. For such a radial bearing,the bearing surface 1012 of elements 1010 mounted to inner race 1002 maybe convexly curved to mate with the concave curvature of bearing surface1008. One or more, or all of the bearing elements 1006 and 1010 may bepartitioned according to any of the embodiments disclosed herein. Theinner race 1002 is positioned generally within the outer race 1004 and,thus, the inner race 1002 and outer race 1004 may be configured so thatthe bearing surfaces 1008 and 1012 may at least partially contact oneanother and move relative to each other as the inner race 1002 and outerrace 1004 rotate relative to each other during use.

The radial-bearing apparatus 1000 may be employed in a variety ofmechanical applications. For example, so-called “roller cone” rotarydrill bits may benefit from a radial-bearing apparatus disclosed herein.More specifically, the inner race 1002 may be mounted to a spindle of aroller cone and the outer race 1004 may be mounted to an inner boreformed within a cone and that such an outer race 1004 and inner race1002 may be assembled to form a radial-bearing apparatus.

Referring to FIG. 12, the thrust-bearing apparatus 900 and/or radialbearing apparatus 1000 may be incorporated in a subterranean drillingsystem. FIG. 12 is a schematic isometric cut-away view of a subterraneandrilling system 1100 that includes at least one of the thrust-bearingapparatuses 900 shown in FIG. 10 according to another embodiment. Thesubterranean drilling system 1100 includes a housing 1102 enclosing adownhole drilling motor 1104 (i.e., a motor, turbine, or any otherdevice capable of rotating an output shaft) that is operably connectedto an output shaft 1106. A first thrust-bearing apparatus 900 a (FIG.10) is operably coupled to the downhole drilling motor 1104. A secondthrust-bearing apparatus 900 b (FIG. 10) is operably coupled to theoutput shaft 1106. A rotary drill bit 1108 configured to engage asubterranean formation and drill a borehole is connected to the outputshaft 1106. The rotary drill bit 1108 is shown as a roller cone bitincluding a plurality of roller cones 1110.

However, other embodiments may employ different types of rotary drillbits, such as a so-called “fixed cutter” drill bit shown in FIGS. 8-9.As the borehole is drilled, pipe sections may be connected to thesubterranean drilling system 1100 to form a drill string capable ofprogressively drilling the borehole to a greater depth within the earth.

A first one of the thrust-bearing assemblies 902 of the thrust-bearingapparatus 900 a is configured as a stator that does not rotate and asecond one of the thrust-bearing assemblies 902 of the thrust-bearingapparatus 900 a is configured as a rotor that is attached to the outputshaft 1106 and rotates with the output shaft 1106. The on-bottom thrustgenerated when the drill bit 1108 engages the bottom of the borehole maybe carried, at least in part, by the first thrust-bearing apparatus 900a. A first one of the thrust-bearing assemblies 902 of the secondthrust-bearing apparatus 900 b is configured as a stator that does notrotate and a second one of the thrust-bearing assemblies 902 of thethrust-bearing apparatus 900 b is configured as a rotor that is attachedto the output shaft 1106 and rotates with the output shaft 1106. Fluidflow through the power section of the downhole drilling motor 1104 maycause what is commonly referred to as “off-bottom thrust,” which may becarried, at least in part, by the second thrust-bearing apparatus 900 b.

In operation, drilling fluid may be circulated through the downholedrilling motor 1104 to generate torque and effect rotation of the outputshaft 1106 and the rotary drill bit 1108 attached thereto so that aborehole may be drilled. A portion of the drilling fluid may also beused to lubricate opposing bearing surfaces of the bearing elements 906of the thrust-bearing assemblies 902.

Thus, PDCs including one or more partitioning cuts as disclosed hereinmay be used in any apparatus or structure in which at least one PDC istypically used. In an embodiment, a rotor and a stator, assembled toform a thrust-bearing apparatus, may each include one or more PDCs(e.g., the PDC of FIG. 3) configured according to any of the embodimentsdisclosed herein and may be operably assembled to a downhole drillingassembly. U.S. Pat. Nos. 4,410,054; 4,560,014; 5,364,192; 5,368,398;5,480,233; 7,552,782; and 7,559,695, the disclosure of each of which isincorporated herein, in its entirety, by this reference, disclosesubterranean drilling systems within which bearing apparatuses utilizingsuperabrasive compacts disclosed herein may be incorporated. Theembodiments of PDCs disclosed herein may also form all or part of heatsinks, wire dies, bearing elements, cutting elements, cutting inserts(e.g., on a roller-cone-type drill bit), machining inserts, or any otherarticle of manufacture as known in the art. Other examples of articlesof manufacture that may use any of the PDCs disclosed herein aredisclosed in U.S. Pat. Nos. 4,811,801; 4,268,276; 4,468,138; 4,738,322;4,913,247; 5,016,718; 5,092,687; 5,120,327; 5,135,061; 5,154,245;5,460,233; 5,544,713; and 6,793,681, the disclosure of each of which isincorporated herein, in its entirety, by this reference.

While various aspects and embodiments have been disclosed herein, otheraspects and embodiments are contemplated. The various aspects andembodiments disclosed herein are for purposes of illustration and arenot intended to be limiting. Additionally, the words “including,”“having,” and variants thereof (e.g., “includes” and “has”) as usedherein, including the claims, shall be open ended and have the samemeaning as the word “comprising” and variants thereof (e.g., “comprise”and “comprises”).

What is claimed is:
 1. A method of partitioning a polycrystallinediamond compact (“PDC”), the method comprising: providing the PDCincluding a polycrystalline diamond (“PCD”) table bonded to a substrateat an interface, wherein the PCD table includes a plurality of bondeddiamond grains, the PDC further including: an exterior working surfacedefined by the PCD table and spaced from the interface; a bottomsubstrate surface defined by the substrate spaced from the exteriorworking surface and the interface; and at least one lateral surfaceextending between the exterior working surface and the bottom substratesurface, the at least one lateral surface including a first portion thatextends away from the exterior working surface to the interface; andcutting at least one of the substrate or the PCD table through athickness of the at least one of the substrate or the PCD table to format least one partition including a first open end laterally spaced froman opposing second open end, the at least one partition exhibiting anon-zero width and dividing the at least one of the substrate or the PCDtable into at least two portions; wherein the at least one partition isformed in one of: the bottom substrate surface and extends at leastpartially through the substrate; or the exterior working surface andextends through at least a majority of the first portion of the at leastone lateral surface and into at least a portion of the substrate.
 2. Themethod of claim 1 wherein cutting at least one of the substrate or thePCD table includes cutting only the substrate.
 3. The method of claim 2wherein the at least one partition extends in the substrate to about0.05 inch or less from the PCD table.
 4. The method of claim 1 whereincutting at least one of the substrate or the PCD table includesgrinding, machining, laser cutting, electro-discharge machining, orcombinations thereof to remove material of the at least one of thesubstrate or the PCD table to form the at least one partition.
 5. Themethod of claim 1 wherein the at least two portions includes at leastthree portions.
 6. The method of claim 1 wherein the at least onepartition extends into the PCD table.
 7. The method of claim 1 whereinthe at least one partition extends through a majority of the thickness.8. The method of claim 1 wherein the at least one partition is a stressrelieving partition.
 9. The method of claim 1, further comprisingleaching at least a portion of the PCD table.
 10. A method ofpartitioning a polycrystalline diamond compact (“PDC”), the methodcomprising: providing the PDC including a polycrystalline diamond(“PCD”) table bonded to a substrate at an interface, wherein the PCDtable includes a plurality of bonded diamond grains, the PDC furtherincluding: an exterior working surface defined by the PCD table andspaced from the interface; a bottom substrate surface defined by thesubstrate spaced from the exterior working surface and the interface;and at least one lateral surface extending between the exterior workingsurface and the bottom substrate surface; and partitioning the substrateand the PCD table by forming at least one cut through the substrate andinto at least a portion of the PCD table, the at least one cutexhibiting a non-zero width, the at least one cut including a first openend laterally spaced from an opposing second open end.
 11. The method ofclaim 10 wherein the at least one cut exhibits a width of about 0.001inches to about 0.002 inches.
 12. The method of claim 10 wherein the atleast one cut extends through an entire thickness of the substrate. 13.The method of claim 10 wherein partitioning the substrate and the PCDtable by forming at least one cut through the substrate and into atleast a portion of the PCD table relieves stresses in the PCD table. 14.The method of claim 10, further comprising leaching at least a portionof the PCD table.
 15. A polycrystalline diamond compact (“PDC”)comprising: a substrate; a polycrystalline diamond (“PCD”) tableincluding a plurality of bonded diamond grains, the PCD table bonded tothe substrate at an interface, the PDC further including: an exteriorworking surface defined by the PCD table and spaced from the interface;a bottom substrate surface defined by the substrate spaced from theexterior working surface and the interface; and at least one lateralsurface extending between the exterior working surface and the bottomsubstrate surface, the at least one lateral surface including a firstportion extending away from the exterior working surface to theinterface; and wherein at least one of the substrate or the PCD tableincludes at least one partition having a non-zero width and including afirst open end laterally spaced from an opposing second open end, the atleast one partition extending a distance through a thickness of the atleast one of the substrate or the PCD table; wherein the at least onepartition is formed in one of: the bottom substrate surface and extendsat least partially through the substrate; or the exterior workingsurface and extends through at least a majority of the first portion ofthe PCD table and into at least a portion of the substrate.
 16. The PDCof claim 15 wherein the at least one partition exhibits a width betweenabout 0.001 inch to about 0.2 inches.
 17. The PDC of claim 15 whereinthe exterior working surface of the PCD table is convex or substantiallyplanar.
 18. The PDC of claim 15 wherein the at least one partitionextends through a majority of the thickness.
 19. The PDC of claim 15wherein the at least one partition is a stress relieving partition. 20.The PDC of claim 15 wherein the PCD table includes a leached portionextending inwardly from the exterior working surface.
 21. A rotary drillbit, comprising: a bit body configured to engage a subterraneanformation; and a plurality of polycrystalline diamond cutting elementsmounted to the bit body, at least one of the plurality ofpolycrystalline diamond cutting elements including: a substrateincluding an interfacial surface and a bottom substrate surface spacedfrom the interfacial surface; a polycrystalline diamond (“PCD”) tableincluding a plurality of bonded diamond grains, the PCD table beingbonded to the interfacial surface of the substrate and including anexterior working surface spaced from the interfacial surface; whereinthe at least one of the plurality of polycrystalline diamond cuttingelements includes at least one lateral surface extending between theexterior working surface and the bottom substrate surface, the at leastone lateral surface including a first portion that extends away from theexterior working surface to the interfacial surface; and wherein the atleast one of the substrate or the PCD table includes at least onepartition including a first open end laterally spaced from an opposingsecond open end, the at least one partition exhibiting a non-zero widthand dividing the substrate or the PCD table into at least two portions;wherein the at least one partition is formed in one of: the bottomsubstrate surface and extends at least partially through the substrate;or the exterior working surface and extends through at least a majorityof the first portion of the at least one lateral surface and into atleast a portion of the substrate.